turck IM33-11-HI/24VDC, IM33-22EX-HI/24VDC, IM33-12EX-HI/24VDC, IM33-11EX-HI/24VDC, IM33-22-HI/24VDC Safety Manual

SAFETY

MANUAL

ISOLATING
TRANSDUCERS

IM33-11EX-HI/24VDC
IM33-11-HI/24VDC
IM33-12EX-HI/24VDC
IM33-22EX-HI/24VDC
IM33-22-HI/24VDC

Sense it! Connect it! Bus it! Solve it!

Hans Turck GmbH & Co. KG • Tel. [phone] • Fax [phone]

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Safety Manual – Isolating Transducers

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1 About this safety manual 5

1.1 Target groups 5

1.2 Explanation of symbols 5

1.3 Abbreviations and terms 5

1.4 Document history 6

2 Notes on devices 6

2.1 Device variants 6

2.2 Scope of delivery 6

2.3 Manufacturer and service 7

3 For your safety 7

3.1 Intended use 7

3.2 Obvious misuse 7

3.3 SIL registration card 7

3.4 General safety regulations 8

4 Device specic information on safety applications 8

4.1 Safety function 8

4.2 Safe state 8

4.3 Functions and operating modes 8

4.3.1 Supply of transmitters 8

4.3.2 Signal transmission 9

4.3.3 Signal doubling 9

4.3.4 Line monitoring 9

4.3.5 Fault acknowledgement 9

4.4 Types of faults and failures 9

4.5 Safety characteristic values 9

4.5.1 FMEDA assumptions 9

4.5.2 Hardware architecture 10

4.5.3 Characteristic values for IM33-… isolating transducers 10

4.6 Recurrent function tests 10

4.7 Useful life 10

4.8 Special regulations and restrictions 11

5 Installation and commissioning 11

5.1 Mounting 11

5.2 Connection 11

5.2.1 Wiring diagrams 11

5.3 Commissioning 13

5.3.1 Selecting transmitters 13

6 Operation, maintenance and repair 13

6.1 Troubleshooting 13

6.2 Maintenance 13

6.3 Repair 14

6.3.1 Returning devices 14

7 Decommissioning and withdrawal from service 14

7.1 Decommissioning 14

7.2 Withdrawing from service 14

8 Appendix – EXIDA FMEDA report Turck 04/07-14 R001 15

Contents

Safety manual

Hans Turck GmbH & Co. KG • Tel. [phone] • Fax [phone]

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Safety Manual – Isolating Transducers

Contents

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About this safety manual

Safety manual

1 About this safety manual

This safety manual contains instructions on the use of devices in safety instrumented systems (SIS). The consid­eration of safety-related values is based on IEC 61508. The safety manual describes the values determined for the
SIL assessment and is only applicable in conjunction with the attached EXIDA FMEDA report Turck 04/07-14 R001.
Read this document carefully before using the device. This will prevent the risk of personal injury or damage to
property or equipment. Keep this manual safe during the service life of the device. If the device is passed on, hand
over this safety manual as well.

DANGER

Malfunction caused by operating errors

Danger to life if safety function fails!

 Observe the instructions contained in this safety manual without fail if the device is to be used in safety-relat-

ed applications.

1.1 Target groups

This safety manual is designed for use by suitably qualified or trained personnel. It must be read and understood
by anyone entrusted with any of the following tasks:

■

Unpacking and mounting

■

Commissioning

■

Testing and maintenance

■

Troubleshooting

■

Disassembly and disposal

1.2 Explanation of symbols

The following symbols are used in this safety manual:

DANGER

DANGER indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

NOTE

NOTE indicates tips, recommendations and important information. The notes contain information, particular op­erating steps that facilitate work and possibly help to avoid additional work resulting from incorrect procedures.



MANDATORY ACTION

This symbol denotes actions that the user must carry out.



RESULT OF ACTION

This symbol denotes the relevant results of actions and procedures.

1.3 Abbreviations and terms

Definition of terms, see IEC 61508-4

DC diagnostic coverage

E/E/PE system electrical/electronic/programmable

electronic system

EUC equipment under control

dangerous failure

no effect failure

no part failure

safe failure

safe state

HFT hardware fault tolerance

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Safety Manual – Isolating Transducers

high demand mode

low demand mode

MooN M out of N channel architecture

MTBF mean time between failures

MTTR mean time to restoration

PFD probability of dangerous failure on

demand

PFD

AVG

average probability of dangerous
failure on demand

PFH probability of a dangerous failure per

hour

SFF safe failure fraction

SIF safety instrumented function Safety function

SIS safety instrumented system

SIL safety integrity level

proof test

proof test interval

1.4 Document history

Rev. Description Date

1.0.0 First edition 02.04.2015

The German version shall be considered the definitive document. Every care was taken in the production of the
translations of this document. If there is any uncertainty in its interpretation, refer to the German version of the
safety manual or contact Turck directly.

NOTE

In all cases use the latest version of this safety manual. Check whether a newer version is available.

2 Notes on devices

2.1 Device variants

This safety manual applies to the following Turck isolating transducers:

IM33-11Ex-Hi/24VDC IM33-22Ex-Hi/24VDC

IM33-11-Hi/24VDC IM33-22-Hi/24VDC

IM33-12Ex-Hi/24VDC

2.2 Scope of delivery

The device is supplied with the SIL registration card.

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For your safety

Safety manual

2.3 Manufacturer and service

Turck supports you in your projects – from the initial analysis right through to the commissioning of your applica­tion. The Turck product database offers you several software tools for programming, configuring or commission­ing, as well as data sheets and CAD files in many export formats. You can access the Product Database directly via
the following address: www.turck.de/produkte
For further inquiries in Germany contact the Sales and Service Team on:
Sales: [phone]
Technical: [phone]
For overseas inquiries contact your national Turck representative.

Hans Turck GmbH & Co. KG
45466 Mülheim an der Ruhr
Germany

3 For your safety

The device is designed according to the latest state-of-the-art technology. Residual hazards, however, still exist.
Observe the following warnings and safety regulations in order to prevent danger to persons and property. Turck
accepts no liability for damage caused by failure to observe regulations.

3.1 Intended use

Isolating transducers are used to operate (intrinsically safe) active or passive 2-wire or passive 3-wire transmitters.
The galvanically isolated (intrinsically safe) analog measuring signal is transmitted from the field to the control­ler. Besides the analog signal, HART® signals can also be transmitted bidirectionally. The devices are designed for
input/output circuits of 0/4…20mA. The input signals are transmitted 1:1. A wire break is detected at an input cur­rent <3.6mA and a short circuit at an input current >21.5mA in accordance with NE requirements, and indicated
accordingly as an output value.

These devices also enable the creation of safety-related systems up to and including SIL2 according to IEC 61508
(hardware fault tolerance HFT = 0). The devices must only be used in safety-related systems if all requirements
stated in this safety manual and the EXIDA report are strictly observed. The information in the EXIDA report applies
when IEC 61508 is used for applications with a low demand mode (device type A for low demand mode). When
used in safety systems, the probability of dangerous failure (PFD) for the entire circuit must be determined and
given due consideration.

3.2 Obvious misuse

When using dual-channel devices in safety circuits, the second channel must not be used to increase the hardware
fault tolerance and thus achieve a higher SIL level.
The IM33-…Ex-HI/24VDC isolating transducers can be installed in zone 2 in accordance with the ATEX Directive;
the IM33-11-HI/24VDC and IM33-22-HI/24VDC isolating transducers must not be installed in explosion hazardous
areas in accordance with the ATEX Directive.

3.3 SIL registration card

NOTE

With safety-related applications, the SIL registration card enclosed with the device must be filled in completely by
the user and returned to Turck without fail.

Hans Turck GmbH & Co. KG • Tel. [phone] • Fax [phone]

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Safety Manual – Isolating Transducers

3.4 General safety regulations

■

It is the responsibility of the user to ensure that the device is used in compliance with the applicable regula­tions, standards and laws.

■

The suitability for specific applications must be assessed by considering the particular overall safety-related
system with regard to the requirements of IEC 61508.

■

The device must only be carried out by trained and qualified personnel.

■

The device must only be commissioned and operated by trained and qualified personnel.

■

A function test must be completed prior to initial operation, after repair and replacement, as well as at the
stipulated interval T[Proof ]

■

When the device is in operation, ensure that the power supply is within the specified voltage range.

■

Ensure that the plug connections and cables are always in good condition.

■

Special application-specific factors such as chemical and physical stresses may cause the premature wear of
the devices and must be taken into consideration when planning systems; take special measures to compen­sate for a lack of experience based values, e.g. through the implementation of shorter test intervals.

■

If faults occur in the device that cause a switch to the defined safe state, measures must be taken to maintain
the safe state during the further operation of the overall control system.

■

Turck must be notified of dangerous failures immediately.

■

A faulty device must be replaced immediately and must not be repaired.

■

The device must be replaced immediately if the terminals are faulty or the device has any visible faults.

■

Interventions and conversions on the device are not permissible. Repairs must only be carried out by Turck.
Return the device to Turck for this (see section “Repair”).

■

Before using the product in safety-related applications, the suitability of the specifications stated in this safety
manual for the particular application (e.g. particular branch-specific requirements and practices) must always
be checked. In cases of doubt please contact the stated manufacturer's address.

4 Device specic information on safety applications

4.1 Safety function

■

Normal operation: The device transmits the 4…20 mA current signals with a tolerance of 2 % of the end value
from the input to the output.

■

Low trip (on wire break): The device switches to the safe state at an input current of < 3.6 mA: A current of < 3.6
mA is output.

■

High trip (on short circuit): The device switches to the safe state at an input current of > 21.5 mA: A current of >

21.5 mA is output.

DANGER

The characteristic values determined apply to the use of an output in safety-related functions. The second output
must not be used for the safety function with signal doubling.

Danger to life due to misuse!

 Only use one output for the safety function with signal doubling.

4.2 Safe state

The safe state is defined as follows:

■

“fail low” status: Output < 3.6 mA

■

“fail high” status: Output > 21.5 mA

4.3 Functions and operating modes

4.3.1 Supply of transmitters

The device supplies transmitters with a supply voltage of ≥ 17 V / 20 mA.

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Device specic information on safety applications

Safety manual

4.3.2 Signal transmission

Signal transmission on 2-channel devices: The input signal is transmitted 1:1 to the associated output.

4.3.3 Signal doubling

Signal doubling: The input signal of channel 1 is transmitted 1:1 at both outputs.

4.3.4 Line monitoring

A wire break is detected at an input current <3.6mA and a short circuit at an input current >21.5mA in accor­dance with NE requirements, and indicated accordingly as an output value.

4.3.5 Fault acknowledgement

Faults do not have to be acknowledged. If the fault is rectified, the device automatically resumes operation.

4.4 Types of faults and failures

Failures must be classified in conjunction with the application into safe (non-hazardous) and unsafe (hazardous)
failures. You as the operator are responsible for this.

NOTE

Turck must be notified immediately of all damage that was caused by a dangerous undetected failure.

A dangerous failure is present if an internal error has caused

■

the device not to respond when required by the process (e.g. does not switch to the defined safe state) or

■

the output current – as opposed to the input current – changes by more than 2 % of the end value.

4.5 Safety characteristic values

4.5.1 FMEDA assumptions

The safety-related characteristic values were determined based on an FMEDA in accordance with IEC 61508. The
FMEDA is based on the following assumptions:

■

The failure rates are constant.

■

The mechanical wear is not considered.

■

The propagation of failures is not relevant.

■

The MTTR repair time after a safe failure is 8 hours (replacement of the device).

■

The device is operated in low demand mode.

■

The failure rates of an external power supply are not considered.

■

The HART® protocol is not used during normal operation but only for the setup, calibration and diagnostics of
the field devices and is not part of the safety function

■

Only one input and one output are part of the safety function.

■

The failure rates used are the Siemens standards SN 29500 at 40 °C .

■

The second channel of a device cannot be used to increase the HFT hardware fault tolerance.

■

The ambient conditions correspond to an average industrial environment, as defined in MIL-HNBK-217-F or IEC
60654-1, Class C (sheltered location).

–

The ambient temperature is normally 40 °C.

–

A safety factor of 2.5 must be applied for ambient temperatures of 60 °C and frequent temperature fluctua­tions

■

The user program in the safety controller is designed so that a wire break (fail low failure) and short circuit (fail
high failure) are detected irrespective of whether it is a safe or dangerous failure in relation to the safety func­tion.

Hans Turck GmbH & Co. KG • Tel. [phone] • Fax [phone]

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Safety Manual – Isolating Transducers

4.5.2 Hardware architecture

The device is considered as a Type A component (non complex). The hardware fault tolerance HFT is 0.

4.5.3 Characteristic values for IM33-… isolating transducers

The device can be used for applications up to SIL 2.
MTBF = MTTF + MTTR = 1/(λ

total

+ λ

not part

) + 8 h = 159 years

Fail-safe state = fail high

Failure category λ

sd

λ

su

λ

dd

λ

du

SFF DC

S

2

DC

D

2

λ

low

= λ

sd

λ

high = λdd

233 FIT 315 FIT 73 FIT 44 FIT 93 % 42 % 62 %

λ

low

= λ

dd

λ

high = λsd

73 FIT 315 FIT 233 FIT 44 FIT 93 % 18 % 84 %

Fail-safe state = fail low

Failure category λ

sd

λ

su

λ

dd

λ

du

SFF DC

S

2

DC

D

2

λ

low

= λ

sd

λ

high = λdd

239 FIT 315 FIT 67 FIT 44 FIT 93 % 43 % 60 %

λ

low

= λ

dd

λ

high = λsd

67 FIT 315 FIT 239 FIT 44 FIT 93 % 17 % 84 %

IM33-… – Average probability of failure on demand

T[Proof] = 1 year T[Proof] = 5 years T[Proof] = 10 years

PFD

AVG

= 1.92 × 10

-4

PFD

AVG

= 9.60 × 10

-4

PFD

AVG

= 1.92 × 10

-3

NOTE

The PFD

AVG

value of the isolating transducers should be designed to be max. 10% of the total permissible PFD

AVG

value for the safety integrity level SIL2. A PFD

AVG

value marked in green means that the PFD value is within the

range of SIL2 in accordance with IEC 61508-1 and is less than 10% of the total value for SIL2. A PFD

AVG

value
marked in yellow indicates that the PFD value is within the range of SIL2 in accordance with IEC 61508-1 but is
more than 10% of the total value for SIL2.

4.6 Recurrent function tests

A function test must be completed prior to initial operation, after each parameter setting, after repair and replace­ment, as well as at the stipulated interval T[Proof ]:

 Ensure that the function test is only carried out by qualified personnel.
 Think first about your safety and the safety of your environment. If in doubt, replace the device.
 Bridge the isolating transducer in the safety controller (process control system) and ensure that safety is main-

tained. You as the operator are responsible for ensuring that safety is maintained.

 Check the transmission behavior of the device with a suitable transducer and measuring device in 1 mA steps.
 With intrinsically safe device variants follow the regulations for Ex protection.
 If all checks have been completed and no faults found, restart the safety circuit.
 Once the test has been completed, document and archive the results.

NOTE

The function test detects more than 90% of the undetected dangerous failures (Du) of the device

4.7 Useful life

The calculated failure rates of the device are valid for a useful lifetime of 8 years.

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Installation and commissioning

Safety manual

4.8 Special regulations and restrictions

NOTE

Each application has its particular conditions of use and ambient requirements. For this reason, the safety-related
assessment of a system must always take the actual process into account – in addition to the general statements
concerning probability of failure, tolerances and failure rates of the components. Special application-specific fac­tors such as chemical and physical stresses may thus cause the premature wear of the devices and must therefore
be taken into consideration when planning systems. Take special measures to compensate for a lack of experience
based values, e.g. through the implementation of shorter test intervals. The estimation of the diagnostic coverage
(DC) can vary from application to application. The estimation of the hardware fault tolerance (HFT) can only take
place if the use of the compliant object is restricted.

5 Installation and commissioning

DANGER

Failure caused by commissioning and operating errors

Danger to life if safety function fails!

 Ensure that the product is only fitted, installed, operated and maintained by trained and qualified personnel.

5.1 Mounting

Observe the mounting instructions in the user manual.

5.2 Connection

Observe the mounting instructions in the user manual.

5.2.1 Wiring diagrams

+ 1

– 2

10 –

7 +

12 –

11 +

0/4...20 mA

III III

3

HART®

GN

I

?

?

?

HHT

PowerPwr

1

+ 1

2

– 3

+ 2

– 3

HART®

HART®

210 Ω

1

0/4...20 mA
(source)
RL ≤ 500 Ω

Fig. 1: Block diagram of the IM33-11Ex-Hi/24VDC

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Safety Manual – Isolating Transducers

+ 1

– 2

10 –

7 +

12 –

11 +

0/4...20 mA

III III

3

HART®

GN

I

?

?

?

HHT

PowerPwr

1

+ 1

2

– 3

+ 2

– 3

HART®

HART®

210 Ω

1

0/4...20 mA
(source)
RL ≤ 500 Ω

Fig. 2: Block diagram of the IM33-11-Hi/24VDC

+ 1

– 2

10 –

7 +

12 –

11 +

III III

3

9 –

8 +

HART®

GN

I

?

?

?

1

210 Ω

1

2

0/4...20 mA
(source)
RL ≤ 500 Ω

0/4...20 mA
(source)
RL ≤ 500 Ω

HHT

PowerPwr

+ 1

2

– 3

+ 2

– 3

HART®

HART®

0/4...20 mA

Fig. 3: Block diagram of the IM33-12Ex-Hi/24VDC

+ 1

– 2

10 –

7 +

12 –

11 +

0/4...20 mA

III III

3

+ 4

– 5

6

9 –

8 +

HART®

GN

I

?

I

?

?

?

?

?

1

2

HART®

210 Ω

210 Ω

1

2

0/4...20 mA
(source)
RL ≤ 500 Ω

0/4...20 mA
(source)
RL ≤ 500 Ω

HHTHHT

PowerPwr

+ 1

2

– 3

+ 4

5

– 6

+ 2

– 3

+ 5

– 6

HART®

HART®

HART®

HART®

Fig. 4: Block diagram of the IM33-22Ex-Hi/24VDC